Woven stretch fabric bath robe

ABSTRACT

A woven fabric bath robe has a torso section and a pair of sleeves connected thereto, at least the torso section comprises a woven web of warp yarns and fill yarns with a first plurality of the fill yarns (and/or the warp yarns) being non-spandex, non-core spun elastomeric yarns and a second plurality of the fill yarns (and/or the warp yarns) being non-elastomeric yarns, with the elastomeric yarns being generally parallel to the worn width of the bath robe, whereby the bath robe is stretchable in the worn width allowing for an expandable sweep.

FIELD OF THE INVENTION

The present invention relates to bath robes and more specifically to bath robes comprised of woven fabric.

BACKGROUND

Bath robes are well known and widely used and typically include a torso section and a pair of sleeves connected thereto. By way of example, bath robes are often formed of woven webs comprised of warp yarns and fill yarns. In many robes, the woven web also includes pile loops and is generally considered to be a terry fabric. While such robes are ubiquitous, they present an inventory and cost problem, especially in the hospitality market such as hotels and motels.

In that regard, many hotels offer bath robes to their visitors, such as for after showering or to go to the pool. But the standard practice has been to provide a typical one-size-fits-all (“OSFA”) bath robe. But an OSFA bath robe does not always work for everyone. Sometimes, the wearer needs a larger or smaller bath robe to be able to wear the robe comfortably. Even where the bath robe may at first appear to fit comfortably, if the wearer stretches his arms, the bath robe is seen to be too skimpy. As a result, the hotel, for example, must also stock some smaller and larger sized bath robes, leading to increased costs and the like.

SUMMARY OF THE INVENTION

The present invention provides a woven fabric bath robe which overcomes certain drawbacks of typical sized woven fabric bath robes. To that end, and in accordance with the principles of the present invention, at least the fill yarns or the warp yarns of the woven web of the bath robe, particularly the torso section thereof if not also the sleeves, include a first plurality of non-spandex, non-core spun elastomeric yarns and a second plurality of non-elastomeric yarns. The torso section is constructed such that the first plurality of elastomeric yarns extend generally parallel to the worn width. The sleeves may also be constructed such that elastomeric yarns extend longitudinally therealong, and the sleeves may be connected to the torso section so as to initially extend in a direction generally parallel to the worn width of the torso section. The inclusion of the non-spandex, non-core spun elastomeric yarns in accordance with the present invention provides an elasticity to the bath robe not previously considered for woven fabric bath robes such that the bath robe is stretchable in a worn width allowing for an expandable sweep. As a result, an OSFA bath robe made in accordance with the present invention is more likely to fit a wider range of wearers, thus reducing the need for a hotel, for example, to inventory or handle as many different sizes of bath robes.

Typical yarns used for woven fabric bath robes have very little “give” to them, such that the bath robe fits only a narrow range of wearer sizes. As a consequence, the worn width (i.e., the lateral size such as between the sleeves of the bath robe or the arms of the wearer) is generally fixed. Similarly, if laid flat, the sweep of the bath robe would also be generally fixed. By virtue of the present invention, however, a typical sized bath robe can accommodate not only wearers who would normally comfortably fit in such a bath robe, but also those who might otherwise find the typical sized bath robe to be too small or skimpy.

Where the fill yarns are the elastomeric and non-elastomeric yarns, the warp yarns may be any typical yarns, such as cellulose-containing, synthetic, or a combination thereof. Where the warp yarns are the elastomeric and non-elastomeric yarns, the fill yarns may be any typical yarns, such as cellulose-containing, synthetic, or a combination thereof. Or the warp and fill yarns might each be the elastomeric and non-elastomeric yarns. The elastomeric and non-elastomeric yarns are advantageously a combination of 100% polyester multifilaments yarns. In that regard, the non-elastomeric yarns may be synthetic filament yarns, such as PET polyester, although other yarns could be used provided they have less shrink as compared to the elastomeric yarns. The non-spandex, non-core spun elastomeric yarns may be a bi-component polyester textile fiber which may include PTT and PET polyester, such as elasterell-p. The non-spandex, non-core spun elastomeric yarns provide an elasticity or stretch to the bath robe in the worn width of between about 2% to about 50% of its unstretched worn width, more particularly between about 5% to about 25%, and most particularly about 20%.

The woven web may be woven as a plain or similar weave so as to define a sheeting-like web and is advantageously woven in an approximately 4 oz. per square yard. Similarly, the amount of non-elastomeric yarns to elastomeric yarns in the warp or in the fill may be in a ratio that is advantageously a multiple of 4:1, such as 4:1 or 12:3, although other ratios could be selected. Further, the insertion pattern of the elastomeric and non-elastomeric yarns may be alternating as respective clusters of the non-elastomeric yarn and of the non-spandex, non-core spun elastomeric yarn. The elastomeric yarns will shrink or crinkle more when laundered than will the non-elastomeric yarns to provide a wash activated patterning to the woven web. As a result, the sheeting-like woven web will have a permanent and irreversible textured/wrinkled pattern which thus provides a bulky look or texture sufficient to provide the comfort and feel desired for bath robes. The woven web may alternatively include pile loops so as to define a terry pile web. The pile loops may be of cotton, with the warp, fill, and pile loop yarns being woven in a three-pick terry weave, by way of example. The amount of non-elastomeric yarns to elastomeric yarns in the warp or in the fill may be in a ratio that may advantageously be 1:1, such as pick-and-pick alternating insertion of the non-elastomeric yarns and the non-spandex, non-core spun elastomeric yarns, although other ratios and alternating insertions could be selected.

By virtue of the foregoing, there is thus provided a woven fabric bath robe which overcomes certain drawbacks of typical sized woven fabric bath robes. That and other advantages of the present invention shall be made apparent from the accompanying drawings and the description thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the embodiments given below, serve to explain the principles of the present invention.

FIG. 1 is a perspective view of a woven fabric bath robe constructed in accordance with the principles of the present invention;

FIG. 2 is an exploded view, not to scale, of a portion of one embodiment of a woven web for the bath robe of FIG. 1;

FIG. 3 is an exploded, cross-sectional view, not to scale, of a portion of a second embodiment of a woven web for the bath robe of FIG. 1; and

FIG. 4 is an exploded view, not to scale, of a portion of the torso section and sleeves of the bath robe of FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

With reference to the FIG. 1, there is shown a perspective view of a woven fabric bath robe 10. Bath robe 10 includes a torso section 12, and a pair of sleeves 14, 15 connected to the left and right edges 16, 17, respectively, of torso section 12 to thus define a worn width between edges 16, 17. With further reference to FIGS. 2 and 3, at least the torso section 12 of the bath robe 10 comprises a woven web 20 a (FIG. 2) or a woven web 20 b (FIG. 3) of warp yarns 22 and fill yarns 24, wherein a first plurality of the fill yarns 24 are non-spandex, non-core spun elastomeric yarns 24′, and a second plurality of the fill yarns 24 are non-elastomeric yarns 24″. The sleeves 14, 15 may also comprise woven web 20 a or 20 b. The elastomeric yarns 24′ provide an elasticity to the woven web 20 a or 20 b. As will be readily appreciated, woven webs 20 a and 20 b are fabric webs.

With further reference to FIG. 4, a rear portion of the bath robe 10 is shown comprising the woven web 20 a for purposes of explaining the principles of the present invention. It will be appreciated that the woven web 20 b could be utilized instead. The fill yarns 24 of the woven web 20 a or 20 b of the torso section 12 extend generally parallel to the worn width, such as between the sleeves 14, 15. Thus, the elastomeric yarns 24′ extend generally parallel to the worn width. The sleeves 14, 15 are connected to the torso section 12 so as to initially extend from the respective edges 16, 17, as at 30, in a direction generally parallel to the worn width, and thus the elastomeric yarns 24′ of the torso section 12. The sleeves 14, 15 may, thereafter, extend in a direction that is down and away from the torso section 12 as seen in FIG. 1. It will also be seen that the fill yarns 24, and particularly the elastomeric yarns 24′, of the sleeves 14, 15 advantageously extend longitudinally along the sleeves 14, 15.

In accordance with the principles of the present invention, due to the non-spandex, non-core spun elastomeric yarns 24′, particularly of the woven web 20 a or 20 b of the torso section 12, the bath robe 10 is stretchable in a worn width between the edges 16, 17 (and thus between the sleeves 14, 15) as indicated by arrow 32 (FIG. 4) allowing for an expandable sweep.

In the woven web 20 a, the warp yarns 22 and the fill yarns 24 may be a plain weave or other similar weave patterns, such that the woven web 20 a defines a sheeting-like web. In one embodiment of woven web 20 a, the warp yarns 22 may be cellulose-containing, synthetic, or a combination thereof. By way of example, the warp yarns 22 may be selected from the group consisting of cotton, cotton/poly, and polyester, and may advantageously be 50% cotton/50% poly spun yarn. In that embodiment, the fill yarns 24 are a combination of 100% polyester multifilament yarns, a first plurality thereof 24′ as previously described being the non-spandex, non-core spun elastomeric yarns, and a second plurality 24″ being non-elastomeric synthetic filament yarns. While the yarns 24′ may be any non-spandex, non-core spun elastomeric synthetic, they may be a bi-component polyester textile fiber , such as 150 denier elasterell-p, which is a combination of PET and PTT polyester. The yarns 24″ may be any non-elastomeric synthetic filament yarn, but one advantageous yarn is 150 denier PET polyester.

Woven web 20 a is advantageously woven in an approximately 4 oz. per square yard. And the amount of yarns 24″ to yarns 24′ may be in a ratio that is advantageously a multiple of 4:1, such as 4:1 or 12:3, although other ratios could be selected. Further, the insertion pattern of the yarns 24 may be alternating as a cluster C1 of the non-elastomeric yarns 24″ and a cluster C2 of the non-spandex, non-core spun elastomeric yarns 24′. While only one cluster C1 and two clusters C2 are shown in FIG. 2, it will be appreciated that there will be a number of such alternating clusters in the woven web 20 a. The non-spandex, non-core spun elastomeric yarns 24′, such as the elasterall-p, will shrink or crinkle more when laundered than will the non-elastomeric yarns 24″. That results in a wash activated patterning to the woven web 20 a giving it a permanent and irreversible textured/wrinkled pattern which thus provides a bulky look or texture sufficient to provide the comfort and feel desired for bath robes.

The stretch/recovery capability of the woven fill yarns 24, due to the elastomeric yarns 24′, is utilized in the width direction, i.e., in the torso section 12 in the worn width extending between the sleeves 14, 15 so as to facilitate an expandable fit. The non-spandex, non-core spun elastomeric yarns provide an elasticity or stretch to the bath robe 10 in the worn width of between about 2% to about 50% of its unstretched worn width, more particularly between about 5% to about 25%, and most particularly about 20%.

In one embodiment of woven web 20 b, the warp yarns 22 and the fill yarns 24 are additionally woven with a plurality of pile loops 34 such that the woven web 24 b defines a terry pile web, also referred to as tufted terry. In that embodiment of the woven web 20 b, the warp and fill yarns 22, 24 thereof may be the same as the warp and fill yarns 22, 24 of the woven web 20 a as described above. The pile loops 34 are advantageously cotton, although other yarns may be used for the pile loops. The yarns 24′ which provide the ability to stretch in the worn width may typically be characterized as non-moisture transporting synthetic filament devoid of moisture transporting fiber. The yarns 22, 24, and 34 may be woven in a three-pick terry weave, by way of example. In the embodiment of the woven web 20 b, the amount of yarns 24″ to yarns 24′ may be in a ratio that is advantageously 1:1, such as a pick-and-pick alternating insertion of yarns 24′ and 24″, although other ratios and alternating insertion could be selected.

A method of forming the bath robe 10 includes obtaining the woven web 20 a or 20 b; forming the torso section 12 from the woven web 20 a or 20 b with the elastomeric fill yarns 24′ advantageously extending generally parallel to the worn width, such as between the left and right edges 16, 17 thereof; forming the pair of sleeves 14, 15 from the woven web 20 a or 20 b; and connecting the torso section 12 and the sleeves 14, 15, such as by sewing the sleeve 14 to the left edge 16 of the torso section 12 and sewing the sleeve 15 to the right edge 17 of the torso section 17, such that the sleeves 14, 15 initially extend in a direction generally parallel to the worn width, and thus the elastomeric fill yarns 24′, of the torso section 12. The method may advantageously also include forming the sleeves 14 with the elastomeric yarns 24′ of the woven web 20 a or 20 b extending generally longitudinally therealong.

In use, a wearer 36 will put his arms 37 through the sleeves 14, 15 of the bath robe 10, with the torso section 12 enveloping his torso 38. If the wearer 36 is larger than would normally be accommodated in the OSFA bath robe 10, the elastomeric yarns 24′ extending generally parallel to the worn width provide a stretch capability in the worn width such that the wearer 36 is still able to comfortably wear the bath robe 10.

By virtue of the foregoing, there is provided a woven fabric bath robe which overcomes certain drawbacks of typical sized woven fabric bath robes.

While the present invention has been illustrated by a description of particular embodiments thereof, and while the embodiments have been described in some detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. By way of example, while the embodiments are described with reference to the elastomeric yarns 24′ and non-elastomeric yarns 24″ comprising the fill yarns 24, alternatively or additionally, the warp yarns 22 could be comprised of such elastomeric and non-elastomeric yarns. Where the warp yarns 22 are so comprised, then it will be the elastomeric warp yarns which would extend generally parallel to the worn width of the torso section 12 and/or longitudinally along the sleeves 14, 15. Where both the warp and the fill yarns 22, 24 are so comprised, then either the elastomeric yarns of the warp or the elastomeric yarns of the fill may be selected to extend generally parallel to the worn width of the torso section 12 and/or longitudinally along the sleeves 14, 15. Additionally, while the non-elastomeric yarns, such as the fill yarns 24″, are advantageously non-elastomeric synthetic filament yarns, they could be natural yarns, or a blend of natural and synthetic yarns, and will still be considered to be non-elastomeric yarns provided they have less shrink as compared to the elastomeric yarns (such as fill yarns 24′) so as to provide a wash activated patterning. The bath robe may also include a hood (not shown), one or more pockets 40, and/or a closure belt 41 and loops 42 constructed from the woven web 20 a or 20 b. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of the general inventive concept. 

Having described the invention, what is claimed is:
 1. A woven stretch fabric bath robe having a torso section defining a worn width and a pair of sleeves connected thereto, at least the torso section comprises a woven web of warp yarns and fill yarns, wherein the warp yarns or the fill yarns include a first plurality of non-spandex, non-core spun elastomeric yarns and a second plurality of non-elastomeric yarns, with the first plurality of elastomeric yarns of extending generally parallel to the worn width whereby the bath robe is stretchable in the worn width allowing for an expandable sweep.
 2. The bath robe of claim 1, the first and second plurality of yarns being fill yarns.
 3. The bath robe of claim 1, the warp yarns being cellulose-containing, synthetic, or a combination thereof.
 4. The bath robe of claim 1, the first and second plurality of yarns being warp yarns.
 5. The bath robe of claim 4, the fill yarns being cellulose-containing, synthetic, or a combination thereof.
 6. The bath robe of claim 1, wherein both the warp yarns and the fill yarns each include a respective first plurality of non-spandex, non-core spun elastomeric yarns and a second plurality of non-elastomeric yarns, with the first plurality of elastomeric yarns of one of either the warp yarns or the fill yarns extending generally parallel to the worn width.
 7. The bath robe of claim 1, each of the sleeves comprises the woven web, the elastomeric yarns thereof extending longitudinally along the sleeve.
 8. The bath robe of claim 1, the second plurality of non-elastomeric yarns and the first plurality of elastomeric yarns being present in the woven web in a ratio of about 4:1.
 9. The bath robe of claim 1, wherein the yarns of the woven web comprise an alternating sequence of respective clusters of the non-elastomeric yarns and of the non-spandex, non-core spun elastomeric yarns.
 10. The bath robe of claim 1, the non-elastomeric yarns being synthetic filament yarns.
 11. The bath robe of claim 1 wherein the warp and fill yarns being woven such that the woven web defines a sheeting-like web.
 12. The bath robe of claim 1, wherein the woven web further comprises a plurality of pile loops, such that the woven web defines a terry pile web.
 13. The bath robe of claim 12 wherein the pile loops are cotton.
 14. The bath robe of claim 12, the second plurality of non-elastomeric yarns and the first plurality of elastomeric yarns being present in the woven web in a ratio of about 1:1.
 15. The bath robe of claim 12, wherein the yarns of the woven web comprise an alternating sequence of the non-elastomeric yarns and the non-spandex, non-core spun elastomeric yarns.
 16. A method of forming a bath robe comprising: obtaining a woven web of warp yarns and fill yarns with the warp yarns or the fill yarns including a first plurality of non-spandex, non-core spun elastomeric yarns and a second plurality of non-elastomeric yarns; forming a torso section having a worn width from the woven web with the first plurality of elastomeric yarns extending generally parallel to the worn width; forming a pair of sleeves from the woven web; and connecting the torso section and the sleeves; whereby the bath robe is stretchable in the worn width allowing for an expandable sweep.
 17. The method of claim 16 further comprising obtaining a woven web of warp yarns and fill yarns wherein only the fill yarns include the first plurality of non-spandex, non-core spun elastomeric yarns and the second plurality of non-elastomeric yarns, and forming the torso section from the woven web with the first plurality of elastomeric yarns of the fill yarns extending generally parallel to the worn width.
 18. The method of claim 17 further comprising obtaining a woven web of warp yarns and fill yarns wherein the warp yarns are cellulose-containing, synthetic, or a combination thereof.
 19. The method of claim 16 further comprising obtaining a woven web of warp yarns and fill yarns wherein only the warp yarns include the first plurality of non-spandex, non-core spun elastomeric yarns and the second plurality of non-elastomeric yarns, and forming the torso section from the woven web with the first plurality of elastomeric yarns of the warp yarns extending generally parallel to the worn width.
 20. The method of claim 19 further comprising obtaining a woven web of warp yarns and fill yarns wherein the fill yarns are cellulose-containing, synthetic, or a combination thereof.
 21. The method of claim 16 further comprising obtaining a woven web of warp yarns and fill yarns wherein both the fill yarns and the warp yarns include a respective first plurality of non-spandex, non-core spun elastomeric yarns and second plurality of non-elastomeric yarns, and forming the torso section from the woven web with the first plurality of elastomeric yarns of one of either the warp yarns or the fill yarns extending generally parallel to the worn width.
 22. The method of claim 16 further comprising forming the sleeves with the first plurality of elastomeric yarns of the woven web extending generally longitudinally therealong.
 23. The method of claim 16 wherein the woven web further includes pile loops, such that obtaining the woven web includes obtaining the woven web with pile loops.
 24. A method of forming a bath robe comprising: weaving warp yarns and fill yarns into a woven web of warp yarns and fill yarns with the warp yarns or the fill yarns including a first plurality of non-spandex, non-core spun elastomeric yarns and a second plurality of non-elastomeric yarns; forming a torso section having a worn width from the woven web with the first plurality of elastomeric yarns extending generally parallel to the worn width; forming a pair of sleeves from the woven web; and connecting the torso section and the sleeves; whereby the bath robe is stretchable in the worn width allowing for an expandable sweep.
 25. The method of claim 24 further comprising weaving pile loops with the warp yarns and fill yarns. 